U.S. patent application number 12/524078 was filed with the patent office on 2010-02-04 for pre-primed roofing membrane.
Invention is credited to William Gorman, Joseph Kalwara, Bernard Obereiner, Ross Robertson.
Application Number | 20100024955 12/524078 |
Document ID | / |
Family ID | 39645076 |
Filed Date | 2010-02-04 |
United States Patent
Application |
20100024955 |
Kind Code |
A1 |
Kalwara; Joseph ; et
al. |
February 4, 2010 |
PRE-PRIMED ROOFING MEMBRANE
Abstract
A roofing membrane assembly includes a membrane having a top
surface, bottom surface, first longitudinal edge and second
longitudinal edge. A first primed area is located at the top
surface along the first longitudinal edge. A second primed area is
located on the bottom surface along the second longitudinal edge. A
tape is secured to the membrane on the first primed area. A first
release liner is positioned over the tape and a second release
liner positioned over the second primed area.
Inventors: |
Kalwara; Joseph;
(Indianapolis, IN) ; Obereiner; Bernard;
(Nobleville, IN) ; Robertson; Ross; (Cicero,
IN) ; Gorman; William; (Mooresville, IN) |
Correspondence
Address: |
BRIDGESTONE AMERICAS, INC.
1200 FIRESTONE PARKWAY
AKRON
OH
44317
US
|
Family ID: |
39645076 |
Appl. No.: |
12/524078 |
Filed: |
January 24, 2008 |
PCT Filed: |
January 24, 2008 |
PCT NO: |
PCT/US08/00930 |
371 Date: |
July 22, 2009 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60897370 |
Jan 24, 2007 |
|
|
|
Current U.S.
Class: |
156/71 ; 264/148;
428/41.3; 428/41.8 |
Current CPC
Class: |
Y10T 428/1476 20150115;
B32B 25/06 20130101; B32B 25/08 20130101; Y10T 428/1471 20150115;
B32B 25/02 20130101; B32B 2419/06 20130101; B32B 7/06 20130101;
Y10T 428/2848 20150115; E04D 5/12 20130101; B32B 2307/748 20130101;
B32B 2307/7265 20130101; Y10T 428/1452 20150115; Y10T 428/14
20150115; B32B 3/08 20130101; B32B 7/12 20130101; E04D 5/148
20130101; B32B 25/14 20130101; B32B 27/32 20130101; E04D 5/142
20130101; E04D 5/143 20130101 |
Class at
Publication: |
156/71 ;
428/41.8; 428/41.3; 264/148 |
International
Class: |
E04F 13/072 20060101
E04F013/072; B32B 33/00 20060101 B32B033/00; B29C 47/00 20060101
B29C047/00 |
Claims
1. A roofing membrane assembly comprising: a membrane having a top
surface, a bottom surface, a first longitudinal edge and second
longitudinal edge; a primed area along one of said first
longitudinal edge on said top surface and said second longitudinal
edge on said bottom surface; and a release liner positioned over
said primed area.
2. A roofing membrane assembly according to claim 1, further
comprising a second primed area along the other of said first
longitudinal edge on said top surface and said second longitudinal
edge on said bottom surface, and a second release liner positioned
over said second primed area.
3. A roofing membrane assembly according to claim 2, further
comprising an adhesive tape positioned on one of said primed area
and said second primed area between said membrane and one of said
release liner and said second release liner.
4. A roofing membrane assembly according to claim 1, further
comprising an adhesive tape positioned on said primed area between
said membrane and said release liner.
5. A roofing membrane assembly according to claim 1, where said
membrane is between about 25 feet to about 400 feet long in the
longitudinal direction.
6. A roofing membrane assembly according to claim 1, where said
membrane is between about 3 feet to about 50 feet wide in the
transverse direction.
7. A roofing membrane assembly according to claim 1, where said
primed area includes a solvent based primer.
8. A roofing membrane assembly according to claim 7, where said
primer contains less than 20% solids.
9. A roofing membrane assembly according to claim 1, where said
membrane is made of EPDM.
10. A method of installing a membrane assembly on a roof surface
comprising: positioning a first membrane assembly on the roof
surface, the membrane having a top surface, a first longitudinal
edge, a first primed area along the first longitudinal edge of the
top surface, and a first release liner positioned over the first
primed area; positioning a second membrane assembly on the roof
surface, the membrane having a bottom surface, a second
longitudinal edge, a second primed area along the second
longitudinal edge of the bottom surface, and a second release liner
positioned over the second primed area; removing one of the first
release liner and the second release liner, thereby creating a
first exposed primer area; applying an adhesive tape to the first
exposed primer area; removing the other of the first release liner
and the second release liner creating a second exposed primer area;
pressing the second exposed primer area against the adhesive tape
to form a lap seam between the first membrane and the second
membrane.
11. A method of installing a membrane assembly on a roof surface
comprising: positioning a first membrane assembly on the roof
surface, the membrane having a top surface, a first longitudinal
edge, a first primed area along the first longitudinal edge of the
top surface, an adhesive tape positioned on the first primed area,
and a first release liner positioned over the adhesive tape;
positioning a second membrane assembly on the roof surface, the
membrane having a bottom surface, a second longitudinal edge, a
second primed area along the second longitudinal edge of the bottom
surface, and a second release liner positioned over the second
primed area; removing both the first release liner and the second
release liner; pressing the second primed area against the adhesive
tape to form a lap seam between the first membrane and the second
membrane.
12. A flashing membrane assembly comprising: a flashing membrane
having a bottom surface; a primed area on said bottom surface of
said flashing membrane; and a release liner positioned over said
primed area.
13. The flashing membrane assembly of claim 12, where said primed
area is substantially the entirety of said bottom surface.
14. The flashing membrane assembly of claim 12, where said flashing
membrane is between about 50 feet to about 100 feet in length.
15. The flashing membrane assembly of claim 13, where said flashing
membrane is between about 3 inches to about 48 inches in width.
16. The flashing membrane assembly of claim 12, where said flashing
membrane is made of EPDM.
17. The flashing membrane assembly of claim 12, where said flashing
membrane is made of neoprene.
18. The flashing membrane assembly of claim 12, where said flashing
membrane is made of polybutadiene rubber.
19. The flashing membrane assembly of claim 12, where said release
liner is a kraft paper.
20. The flashing membrane assembly of claim 12, where said release
liner is a polyolefin film.
21. The flashing membrane assembly of claim 12, where said primed
area includes a solvent based primer having less than 20%
solids.
22. A method of making a pre-primed flashing membrane assembly
comprising: extruding a flashing membrane onto a release liner and
cutting the flashing membrane to a desired length and width;
winding the flashing membrane and release liner into a roll, with
the release liner separating the successive layers of flashing
membrane; simultaneously unwinding the roll of flashing membrane
and separating the release liner from the flashing membrane;
applying a primer to one side of the flashing membrane creating a
primed surface on a primed flashing membrane; allowing solvents in
said primer to flash-off; positioning the release liner over the
primed surface of the primed flashing membrane, with the release
liner being held in place by the tackiness of the primer.
23. The method of claim 19, further comprising the step of rolling
the primed flashing membrane and release liner into a roll.
24. The method of claim 21, where the step of curing the primer
includes subjecting the primed flashing membrane to circulating
air.
25. The method of claim 19, where the step of applying the primer
is accomplished with a metered priming rod.
Description
[0001] This application claims the benefit of U.S. Provisional
Patent Application Ser. No. 60/897,370, filed on Jan. 24, 2007,
which is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] One or more embodiments of the present invention relate to a
roofing membrane including a pre-applied adhesive primer. In other
embodiments a roofing membrane may be provided including a
pre-applied adhesive primer, a pre-applied adhesive tape and
combinations thereof. In still other embodiments of the present
invention a roofing flashing may be provided including a
pre-applied adhesive primer and a release liner.
BACKGROUND OF THE INVENTION
[0003] The construction industry commonly uses single ply membranes
to provide a waterproof barrier on flat or low-slope roofs. It is
prohibitively expensive and difficult to produce and transport a
single membrane that is sized to cover an entire roof surface,
thus, a plurality of individual membranes are provided and oriented
in an overlapping arrangement. The overlapping portions, or
splices, of these individual membranes must be secured together to
ensure that the plurality of membranes form a single waterproof
surface.
[0004] One attachment approach is to secure the adjoining membranes
together using an adhesive tape. These tapes are positioned between
adjacent membrane surfaces and when such surfaces are brought
together, the membranes are thereafter secured together. In order
to ensure that these tapes effectively bond the adjoining
membranes, the areas where tape application occurs should be
prepared using a primer. The primer application removes dirt and
other debris that may inhibit bonding. Further, the primer leaves a
tacky surface upon which the adhesive tape is applied. This
preparation process enhances the adhesion of the tape and
consequently helps prevent leaking and/or separation.
[0005] Currently, primers are applied to the membranes while in the
field, just before the tape adhesive is applied to the membrane.
The tape adhesive is packaged on release liners, which may be paper
or plastic based material possessing engineered release
characteristics to prevent unwanted adhesion and allow proper
unrolling and placement of tape on the primed membrane. After the
tape is applied to the primed membrane, the release liner is
removed to expose the top side of the tape adhesive. The
overlapping primed portion of the adjoining membrane is then mated
to the tape adhesive to affix the two membranes together and create
a water tight barrier at the lap areas between adjacent membrane
panels.
[0006] Field priming of the membrane panels is performed by roofing
mechanics. During application in the field, roof mechanics are
exposed to the primer chemicals and solvents by direct physical
contact during the dispensing and application of the primer and
indirectly to the primer's solvent fumes and volatile organic
chemicals during the flash-off period.
[0007] Field priming of the membrane panels is also subject to
improper application. For example, roof mechanics may not apply
enough primer or apply it unevenly. They may apply the tape before
the flash-off period is complete, leading to a degradation of the
resulting tape adhesive bond. The mechanic may apply the tape too
long after primer application allowing dirt and moisture to collect
on the primed surfaces. In each of the above instances, the
integrity of the field seams may be jeopardized.
[0008] In addition to roofing membrane panels, roof flashing also
conventionally requires application of an adhesive primer as
discussed above. Roof flashing is commonly available to contractors
in narrow rolls, which are typically used for repairs or for detail
work on roofing systems, and is secured to the roofing membranes or
an underlying substrate by use of adhesive tape similar to that
used in conjunction with the roof membranes. Thus, the application
of the adhesive-primer to flashing at the jobsite is subject to the
same limitations and disadvantages as with the on-site application
of membrane primers. Particularly, seams having compromised
integrity due to improper application of the primer can be a
problem to roofing mechanics.
[0009] Thus, there exists a need in the art for means to provide
factory-primed areas of roofing membranes and roof flashing in a
manner that reduces the risk of roofer misapplication and/or
rooftop contamination, as well as reduces the exposure of workers
to harmful chemicals. Further, there exists a need to standardize
the priming operation to facilitate the receipt of tape
adhesive.
SUMMARY OF THE INVENTION
[0010] One or more embodiments of the present invention provide a
roofing membrane assembly including a membrane having a top surface
and a bottom surface and a first longitudinal edge and a second
longitudinal edge, a first primed area on the top surface along the
first longitudinal edge, a second primed area on the bottom surface
along the second longitudinal edge, a tape secured to the membrane
on one of the first primed area and the second primed area, a first
release liner positioned over the tape; and a second release liner
positioned over the other of the first primed area and the second
primed area.
[0011] One or more embodiments of the present invention also
provides a roofing membrane assembly including a membrane having a
top surface and a bottom surface and a first longitudinal edge and
a second longitudinal edge, a first primed area on the top surface
along the first longitudinal edge, a second primed area on the
bottom surface along the second longitudinal edge, a first release
liner positioned over the first primed area; and a second release
liner positioned over the second primed area.
[0012] One or more embodiments of the present invention also
provides a roofing membrane assembly including a membrane having a
top surface and a bottom surface and a first longitudinal edge and
a second longitudinal edge, a first primed area on the top surface
along the first longitudinal edge, a second primed area on the
bottom surface along the second longitudinal edge, and a release
liner positioned over each primed area along one of the first
longitudinal edge of the top surface and the second longitudinal
edge of the bottom surface.
[0013] One or more embodiments of the present invention also
provides a flashing assembly including a flashing membrane having a
bottom surface, a primed area on the bottom surface of the flashing
membrane, and a release liner positioned over the primed area.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is a fragmentary perspective view of a membrane
assembly made according to the methods of the present
invention;
[0015] FIG. 2 is a fragmentary perspective view showing the removal
of the release liner from a membrane of the membrane assembly of
FIG. 1;
[0016] FIG. 3 is a fragmentary perspective view showing the
application of an adhesive tape to the first membrane;
[0017] FIG. 4 is a fragmentary perspective view showing the first
membrane and the second membrane adhered to one another at a lap
seam;
[0018] FIG. 5 is a fragmentary perspective view of a first
alternate membrane assembly made according to the methods of the
present invention;
[0019] FIG. 6 is a fragmentary perspective view of a pair of
membranes of the first alternate membrane assembly of FIG. 5,
positioned adjacent to one another and with release liner of the
bottom membrane being removed;
[0020] FIG. 7 is a fragmentary perspective view showing the removal
of the release liner from the top membrane and application of an
adhesive tape on a primed area of the bottom membrane of FIG.
6;
[0021] FIG. 8 is a fragmentary perspective view of a second
alternate membrane assembly made according to the methods of the
present invention; and
[0022] FIG. 9 is a fragmentary perspective view of a pair membranes
of the second alternate membrane assembly of FIG. 8, positioned
adjacent to one another and with release liners being removed.
[0023] FIG. 10 is a fragmentary perspective view of a flashing
membrane assembly with a release liner being removed according to
the third alternate embodiment of the present invention.
DETAILED DESCRIPTION OF THE ILLUSTRATIVE EMBODIMENTS
[0024] Referring now to FIG. 1, a membrane assembly is shown,
generally indicated by the numeral 10. Membrane assembly 10
includes a membrane 12 that is preferably waterproof and weather
resistant. In one or more embodiments the membranes of the present
invention may be a thermoset material. In other embodiments the
membrane may be a thermoformable material. In one or more
embodiments, the membrane may be EPDM based. In other embodiments,
the membrane may be TPO based. In these or other embodiments, the
membrane may be flexible and capable of being rolled up for
shipment. In these or other embodiments the membrane may include
fiber reinforcement.
[0025] Membrane 12 includes a top surface 14 and a bottom surface
16, which is generally spaced from top surface 14. Membrane 12 may
be in the form an elongated strip and include a pair of spaced
longitudinal edges 18a and 18b. In one or more embodiments,
membrane 12 may be from about 25 to about 400 feet (8-122 m) in the
longitudinal direction. In these or other embodiments, membrane 10
may be from about 3 to about 50 feet (0.9-15 m) in the transverse
direction.
[0026] In the present embodiment, a primer 20 is factory applied on
a portion of top surface 12 adjacent longitudinal edge 18a, forming
a primed area 21. Primer 20 may be solvent based. In one or more
embodiments polymeric material may be suspended or dissolved in the
solvent. In one or more embodiments, the primer may be less than 20
percent solids. In other embodiments the primer may be less than 16
percent solids. In still other embodiments the primer may be less
than 10 percent solids. In one or more embodiments the polymeric
material may include polymer tacifying resins. Examples of suitable
solvent-based primers may include Firestone QuickPrime.TM. Plus,
Firestone QuickPrime.TM. Plus LVOC, ADCO HSSP-1, Ashland
PLIOSEAL.TM. 9705. In one or more embodiments, primer 20 is
disposed adjacent to substantially the entire longitudinal edge
18a. In these or other embodiments, primer 20 may extend from
longitudinal edge 18a along top surface 20 in a transverse
direction for a desired distance, which may be about 3 to 12 inches
(76-305 mm) from the longitudinal edge. Those skilled in the art
will appreciate that the width of the primed area may vary and may
be designed based upon the width of the desired adhesive.
[0027] As is known in the art, primers typically include solvents
and carrier components that, upon exposure to air, will vaporize.
After application to membrane 12, the volatile portion of the
primer substantially vaporizes, with the solids portion remaining
on membrane 12 being thereafter ready to promote adhesion as will
be hereinafter described. This vaporization period is also known as
the "flash-off" period. Thus, it should be appreciated that after a
sufficient "flash-off" period, primed area 21 is generally tacky
and substantially free from dirt, debris or other contaminates that
may inhibit adhesion between adjoining membranes. After solvent
flash off, the remaining solids portion of the primer may be
described as a polymeric film. In one or more embodiments, the film
includes a thickness of greater than 0.001 inches (25 .mu.m). In
still other embodiments, the film includes a thickness of less than
0.007 inches (178 .mu.m). In other embodiments, the film includes a
thickness of less than 0.005 inches (127 .mu.m). In still other
embodiments, the film includes a thickness of less than 0.003
inches (76 .mu.m).
[0028] Though the primer of the present invention is tacky, it does
not exhibit the same adhesive qualities as the adhesive tape
described herein below. For example, a lap seam formed with just
two primed surfaces and no tape may be characterized by a peel
strength of less than 1.0 pli (1.75 N/cm). A lap seam including
primed surfaces and adhesive tape may be characterized by a peel
strength of at least 1.8 pli (3.15 N/cm). In other embodiments the
peel strength of the taped lap seam may be at least 2 pli (3.5
N/cm). In still other embodiments the peel strength of the taped
lap seam may be at least 2.2 pli (3.85 N/cm). As is known in the
art, peel strength can be determined by ASTM D413.
[0029] Membrane assembly 10 further includes a release liner 22
that is positioned over primer 20 to prevent contaminates from
contacting and collecting on the primed area. The tackiness of
primer 20 holds release liner 22 thereon. Release liner 22 may
include a thin film or coating to which the primer may form a
temporary bond. However, this bond can be readily broken by
applying minimal tension. Release liner 22 may advantageously
provide protection to primed area 21 during storage or shipment,
and may remain in place until a roof mechanic removes it during
rooftop membrane installation prior to installation of tape
adhesive. In one or more embodiments release liner 22 may be
between approximately 1 and 9 mils (25-229 .mu.m) in thickness, in
other embodiments between approximately 1 and 7 mils (25-178 .mu.m)
in thickness, in still other embodiments between approximately 2
and 6 (51-152 .mu.m) mils in thickness, and in yet other
embodiments between approximately 2 and 4 (51-102 .mu.m) mils in
thickness.
[0030] In one or more embodiments, release liner 22 may include a
paper or cellulosic structure coated with a polymeric coating. In
other embodiments, release liner 22 may include a homogeneous
polymeric structure; for example, release liner 22 may include a
polyester or polyolefin film. Suitable materials for release liner
22 include polypropylene, polyester, high-density polyethylene,
medium-density polyethylene, low-density polyethylene, polystyrene
or high-impact polystyrene. Such polymeric materials offer a number
of advantageous properties, including high moisture resistance,
good resistance to temperature fluctuations during processing and
storage, high tear resistance. In one or more embodiments, these
release liners may also be provided with anti-static surface
coatings. In addition to the above polymeric release liner
materials, release liner 22 may also be made of kraft paper.
[0031] Thus membrane assembly 10 includes a factory applied primer
that is covered and protected by a release liner. By applying the
primer in a controlled factory environment, contamination is
minimized. Further, factory application of primer 20 allows for
additional safety precautions during the "flash-off" period.
Specifically, proper ventilation may be ensured so that the
exposure of workers to harmful fumes is prevented. Further, this
method allows metered application of the primer and enables more
effective and standardized scrubbing and preparation of the
membrane. In one or more embodiments, factory application includes
application of primer or adhesive in the location where the
membrane is manufactured. In these or other embodiments, factory
application includes application of primer or adhesive in a
location where final fabrication of the membrane assembly takes
place; that is, where the primer and release liner are applied to
the membrane prior to delivery to the roof. In any event, factory
application includes application of the primer or adhesive at a
location that is distinct from where the membrane is secured to the
roof (e.g. job site), and is typically at a location of final
fabrication of the membrane assembly prior to shipment of the
membrane assembly to a storage facility or prior to shipment to the
job site. In one or more embodiments, factory application of primer
may be referred to a pre-priming.
[0032] A method of installing membrane assembly 10 will now be
described with reference to FIG. 2. In a first step, membrane
assembly 10 is positioned on a roof surface. The roof surface may
include a roof deck 24 that supports the various roof components.
An insulation layer 26 may be provided on top of roof deck 24 that
helps prevent thermal gain during warm periods and thermal loss
during cold periods.
[0033] In a second step, a second membrane 12' is positioned next
to first membrane 12. A primer 20' may be applied to bottom surface
16' of second membrane 12' along longitudinal edge 18b' to form a
primed area 21'. The solvent portions of primer 20' are then
allowed to flash off.
[0034] In a third step, release liner 22 is pulled away from
membrane 12, exposing primed area 20. Referring now to FIG. 3, in a
fourth step, an adhesive tape 30 is applied proximate to
longitudinal edge 18a on primed area 21 of membrane 12. The
adhesive tapes that may be used include a solid adhesive, which may
also be referred to as a solid adhesive strip, and may include
those that are conventional in the art. In one or more embodiments,
the adhesive tape may include EPDM and/or butyl rubber. In one or
more embodiments the adhesive tapes include at least 85 percent
solids. In other embodiments, the adhesive tapes include at least
90 percent solids. In other embodiments, the adhesive tapes include
at least 95 percent solids. In still other embodiments the adhesive
tapes include at least 99 percent solids. In one or more
embodiments, the adhesive tape includes a thickness of greater than
0.007 inches (0.178 mm). In other embodiments, the tape includes a
thickness greater than 0.01 inches (0.25 mm). In still other
embodiments, the adhesive tape includes a thickness greater than
0.1 inches (2.54 mm). Useful adhesive tapes are disclosed in U.S.
Pat. Nos. 6,120,869, 5,888,602, 5,859,114, 5,733,621, 5,612,141,
5,563,217, 5,545,685, 5,504,136, 5,242,727, 4,932,171, 4,849,268,
4,657,958, 4,855,172, 4,588,637, 4,539,344, and 4,426,468 which are
incorporated herein by reference. Useful tapes are commercially
available including those available under the tradenames
QuickSeam.TM. (Firestone), PLIOSEAL.TM. (Ashland), 510.TM. (Adco),
505.TM. (Adco).
[0035] In a fifth step, shown in FIG. 4, the primed area 21' of
bottom surface 16' of second membrane 12' is pressed into contact
with adhesive tape 30. In this manner, a water resistant lap seam
32 is formed between first membrane 12 and second membrane 12'. As
is evident, a time savings is achieved by pre-applying the primer
prior to roof installation, as only second membrane 12' requires
in-field priming. Likewise, primer solvent fumes are reduced and
contamination risk is minimized.
[0036] It should be appreciated that the above referenced method
may be varied without departing from the teachings of the present
invention. For example, the factory primed area 21 may be
positioned to face toward the roof deck, as primed area 21' of
second membrane 12'. Further, tape 30 may be applied first to the
primed area 21' of second membrane 12'.
[0037] Referring now to FIG. 5, a first alternate membrane assembly
is shown, generally indicated by the numeral 50. Membrane assembly
50 includes a membrane 52 having a top surface 54 and a bottom
surface 56. Membrane 52 may be in the form an elongated strip and
include a pair of spaced longitudinal edges 58a and 58b. In one or
more embodiments, membrane 52 may be from about 25 to 400 feet
(8-122 m) in the longitudinal direction. In these or other
embodiments, membrane 32 may be from about 3 to 50 (0.9-15 m) feet
in the transverse direction.
[0038] A primer 60 is disposed on a portion of top surface 54
adjacent longitudinal edge 58a forming a first primed area 62. In
one or more embodiments, primer 60 is factory applied adjacent to
substantially the entire longitudinal edge 58a. In these or other
embodiments, primed area 62 may extend from longitudinal edge 58a
along top surface 54 in a transverse direction for a desired
distance, which may be about 3 to 12 inches (76-305 mm). Primer 60
is also disposed on a portion of bottom surface 56 adjacent
longitudinal edge 58b, forming a second primed area 64. In one or
more embodiments, primer 60 is factory applied adjacent to
substantially the entire longitudinal edge 58b. In these or other
embodiments, second primed area 64 may extend from longitudinal
edge 58b along top surface 54 in a transverse direction for a
desired distance, which may be about 3 to 12 inches (76-305
mm).
[0039] Membrane assembly 50 further includes a first release liner
66 that is positioned over first primed area 62, and a second
release liner 68 positioned over second primed area 64. As
described above, the tackiness of primer 60 holds release liners 66
and 68 thereon.
[0040] A method of installing first alternate membrane assembly 50
will now be described with reference to FIG. 6. In a first step, a
first membrane assembly 50 is positioned on a roof surface with a
second membrane assembly 50' adjacent thereto. In a second step,
release liner 66 is pulled away from first membrane 52, exposing
first primed area 62. Referring now to FIG. 7, in a third step, an
adhesive tape 70 is field applied proximate to longitudinal edge
58a on the first primed portion 62 of membrane 52.
[0041] In a fourth step, second release liner 68' is pulled away
from second membrane 52' to expose second primed area 64'. Finally,
in a fifth step, shown in FIG. 4, second primed area 64' of second
membrane 52' is pressed into contact with tape 70. In this manner,
a water resistant lap seam 32 is formed between first membrane 52
and second membrane 52'. As is evident, an installation time
savings is achieved by factory-applying the primer along opposed
edges and alternately on the bottom and top surface. In the present
embodiment, no in-field priming is required. In this manner, primer
solvent fumes are greatly reduced, limiting VOC emissions, and
minimizing field contamination risks. Further, it is ensured that
the correct amount of primer is uniformly applied to membranes 52,
52'. Still further, this method ensures the proper preparation of
the membranes 52, 52'.
[0042] It should be appreciated that the above referenced method
may be varied without departing from the teachings of the present
invention. For example, tape 70 may be applied first to the primed
surface 64' of second membrane 52'.
[0043] Referring now to FIG. 8, a second alternate membrane
assembly is shown, generally indicated by the numeral 100. Membrane
assembly 100 includes a membrane 102 having a top surface 104 and a
spaced bottom surface 106. Membrane 100 may be in the form an
elongated strip and include a pair of spaced longitudinal edges
108a and 108b. In one or more embodiments, membrane 102 may be from
about 25 to 400 feet (8-122 m) in the longitudinal direction. In
these or other embodiments, membrane 102 may be from about 3 to 50
feet (0.9-15 m) in the transverse direction.
[0044] A primer 110 is disposed on a portion of top surface 102
adjacent longitudinal edge 108a forming a first primed area 112. In
one or more embodiments, primer 110 is disposed adjacent to
substantially the entire longitudinal edge 108a. In these or other
embodiments, primed area 112 may extend from longitudinal edge 108a
along top surface 104 in a transverse direction for a desired
distance, which may be about 3 to 12 inches (76-305 mm).
[0045] Primer 110 is also disposed on a portion of bottom surface
106 adjacent longitudinal edge 108b, forming a second primed area
114. In one or more embodiments, primer 110 is disposed adjacent to
substantially the entire longitudinal edge 108b. In these or other
embodiments, primed area 114 may extend from longitudinal edge 108b
along top surface 104 in a transverse direction for a desired
distance, which may be about 3 to 12 inches (76-305 mm).
[0046] Membrane assembly 100 further includes an adhesive tape 116
on top surface 102 adjacent longitudinal edge 108a. Adhesive tape
116 may be any conventional adhesive tape known to those skilled in
the art. Adhesive tape 116 is provided on top of primed area 112 to
ensure proper adhesion to membrane 102. A first release liner 118
is positioned over adhesive tape 116, and a second release liner
120 is positioned over second primed area 114. The tackiness of
adhesive tape 116 and primer 110 respectively holds release liners
118 and 120 thereon.
[0047] A method of installing second alternate membrane assembly
100 will now be described. In a first step, a first membrane
assembly 100 is positioned on a roof surface with a second membrane
assembly 100' adjacent thereto. With reference now to FIG. 9, in a
second step, first release liner 118 is removed from tape 116 on
first membrane 102, thereby exposing adhesive tape 116. Further,
second release liner 120' is pulled away from second primed area
114' of second membrane 100' to expose second primed area 114'.
Finally, in a fourth step, shown in FIG. 4, second primed area 114
of second membrane 102' is pressed into contact with tape 116. In
this manner, a water resistant lap seam 32 is formed between first
membrane 102 and second membrane 102'.
[0048] As is evident, an installation time savings is achieved by
pre-applying the primer so that no in-field priming is required.
Further time savings are realized by pre-applying the adhesive tape
prior to installation.
[0049] It should be appreciated that the above referenced method
may be varied without departing from the teachings of the present
invention. For example, factory applied tape 116 may be positioned
on second primed area 114' second facing toward the roof deck.
Referring now to FIG. 10, a third alternative embodiment of the
invention is shown. In this embodiment a flashing assembly is
provided and is generally indicated by the numeral 150. Flashing
assembly 150 includes a flashing membrane 152 having a top surface
154 and a spaced bottom surface 156. Flashing membrane 152 may of
the same materials as used to make the membranes described
hereinabove, such as EPDM, and may be used to repair existing
membrane assemblies, in the installation of detail work on a roof
assembly, as a batten cover, as a gravel stop flashing, or as
perimeter flashing. Flashing membrane 152 may also be made of other
materials, such as Neoprene.TM. (Dupont) or polybutadiene rubber,
and may be provided in a cured, partially cured, or uncured state.
Flashing membrane 152 may be in the form of an elongated and narrow
strip and may include a pair of spaced longitudinal edges 158A and
158B. In one or more embodiments flashing membrane 152 may be from
about 50 to about 100 feet (15-30 m) in the longitudinal direction.
In these or other embodiments flashing membrane 152 may be from
about 3 to about 48 inches (76-1219 mm) wide in the transverse
direction. In these or other embodiments flashing membrane 152 may
be from about 0.030 to 0.075 inches (762-1905 .mu.m) thick in the
direction between top surface 154 and bottom surface 156.
[0050] A primer 160 is disposed on at least a portion of bottom
surface 156. In one or more embodiments, the primer is factory
applied. Primer 160 may include those primers described hereinabove
as discussed with respect to roof membrane assemblies. In a
preferred embodiment, as shown in FIG. 10, primer 160 is disposed
on substantially all of bottom surface 156. In other embodiments,
primer 160 may be disposed along longitudinal edges 158A and 158B
of bottom surface 160. A release liner 162 is positioned over
primed bottom surface 156. In one or several embodiments release
liner 162 may be a silicone treated kraft paper. In other other
embodiments release liner 162 may be made of any material listed
above with respect to the pre-primed membrane release liners.
Release liner 162 may cover substantially all of bottom surface
156, or only those parts of bottom surface 156 that are provided
with primer 160, and is held in place by the tackiness of primer
160. In other embodiments release liner 162 may be slightly larger
than bottom surface 156 such that it overhangs longitudinal edges
158A and 158B, thereby facilitating peeling off of release liner
162 when so desired.
[0051] A method of manufacturing flashing assembly 150 will now be
described. In a first step flashing membrane 152 is formed through
an extrusion die, as is known to persons skilled in the art.
Flashing membrane 152 is extruded onto release liner 162 in an
approximate length of between 50 and 100 feet. The uncured flashing
membrane 152 and release liner 162 is then wound into a roll, with
release liner 162 preventing the successive layers of membrane 152
from sticking together. The roll is then mounted onto a primer
application device. The roll of flashing membrane 152 is then
unwound and the release liner is simultaneously separated from
bottom surface 156 of flashing membrane 152. Flashing membrane 152
then proceeds across or through a primer applicator where a
measured amount of primer 160 is applied to bottom surface 156. In
one or more embodiments, the primer applicator may be a metering
rod, spray applicator, a roller, brushes, or a dipping mechanism.
Primer 160 may then be dried by a combination of heat and
circulated air. In a final step, the same release liner 162 upon
which the flashing membrane was extruded is brought back into
contact with primed bottom surface 156 just prior to flashing
membrane 152 being again wound into a roll with release liner 162
separating the successive layers. In this way a flashing membrane
152 having a pre-primed surface 156 and a protective release liner
162 may be produced.
[0052] It should be appreciated that practice of the present
invention may provide a method for covering a roof top with a
membrane, particularly a thermoset membrane, in the absence or
substantial absence of the use of volatile organic compounds such
as those used in the prior art for primers and liquid adhesives.
Inasmuch as certain embodiments of the present invention provide
membrane with both factory-applied primed surfaces and
factory-applied adhesive surfaces, the vast majority of the area of
a flat or low-sloped roof can be covered with little or no volatile
organic compounds being used. In fact, the use of volatile organic
compounds, such as primers, can be further reduced when the
pre-primed and factory-applied adhesive membrane assemblies are
used in conjunction with the pre-primed flashing assemblies. When
these assemblies are used in conjunction, the need for volatile
organic compounds, such as primers, can be eliminated or at least
greatly reduced inasmuch as they may only be needed in certain
situations such as cut lap seems.
[0053] Various modifications and alterations that do not depart
from the scope and spirit of this invention will become apparent to
those skilled in the art. This invention is not to be unduly
limited to the illustrative embodiments set forth herein.
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